Mcdonnell Aircraft Composites Manufacturing Experiencing Growth

McDonnell Aircraft Company (MCAIR), a division of McDonnell Douglas Corporation, has an extensive composites manufacturing background. Beginning with the development of boron/epoxy rudders for the F-4 in the '60's, to. F-15 production of composites empennage and speedbrake in the early 70s, to the primary structures built for the F/A-18 and AV-8B in the 80s, we have been pioneering advanced composites production. Key breakthrough technologies along the way include automation of ply fabrication using N/C Lasercutters, N/C Knife Cutters, and automated nesting systems, and in-house developed automated core carving machines, automated ultrasonic scanners and in-motion x-ray systems. Processing innovations focused on streamlining part flow and labor savings. Innovative tooling development allowed complex cocured assemblies to be built. We have grown to processing over 2000 pounds of advanced composite materials per day, in a production area of more than 550,000 square feet, supported with more than 1000 dedicated composites production and support personnel. Key lessons learned from this growth are teamwork, with upfront manufacturing involvement in part design; continued technology development; and commitment – to resources and quality. With this philosophy, we look forward to the future, to prepare for ever increasing composite applications.